History of anilox volume measurement | 83

The history of anilox

volume measurement
Anilox volume is one of the main reasons for density variation on press during set-up, writes Phil Hall, managing director
of Troika Systems

M
ost flexographic printers, whether narrow In the example pictured, if the sharp Many manufacturers developed their
web, wide web or corrugated, have pyramid were accurately measured at own method of liquid volume checking,
experienced the frustration of time and 3 volume, the flattened straight cut cell however they needed a reference point
material wastage with prolonged press set-up to would have a volume of over 8 volume, from which to use when stating the
achieve the correct densities required for jobs. the middle flattened-pyramid, which is volume of the aniloxes. If they had done
It appears to be standard procedure to blame first comparable to the early ceramic engraved their calculations on the sharp cell above,
the ink or what the ink technicians have done, then cells, would have a volume (if measured that volume would be very different to
the doctor blade set-up, the substrate and the plates; accurately) of approximately 6 volume. those that made their reference from the
finally, when all else fails, to consider the aniloxes. Measurements with a large variation normal cell, and certainly very different
The condition and actual volume of the anilox in readings were good enough at that from the U-Shape straight cut, wide
needs to be known to minimize press set-up time time, simply because flexo was still in its bottom cell example. This explains why
and cost. Accurate anilox volume measurement is a evolutionary stages and certainly nowhere there can be a very real difference in the
recent part of the evolution of flexographic printing, near the quality we have today. ink carrying capacity of aniloxes from
which in reality was never possible historically. different manufacturers, despite the
This article does not discuss the measurement aniloxes document stating they are of the
of screen count (LPI or LPCM) or the screen angles The condition and same volume.
or cell shapes, which can be hexagonal, elongated
hex or an open cell structures (ie tri-helical or Apex actual volume of the
GTT) – all of which are easily measured with the
AniCAM and Anilox QC software, and should be
anilox needs to be
checked when receiving new aniloxes from the
manufacturers for possible errors in manufacturing
known to minimize
which will cause many hours of frustration and press set-up time
lost production time and waste if not found before
running on press. and cost
History of volume measurement methods As time progressed, laser ablating of
The methods of volumetric measurement on laser longer lasting ceramic aniloxes was a real
ablated ceramic rolls, as with any science, has step forward in anilox manufacturing. This
progressively developed and evolved into something allowed the evolution of higher screen
that can now be described as accurate. counts and hexagonal cell structures
Originally the measurement method was, quite (30 and 60 degree) also over time the
naturally, copied from the mechanically engraved evolution of complex open cell structures,
charts where the screen count and the opening of all of which have really advanced the
the cell was easily established. Knowing the angles quality of flexo printing.
of the engraving tool, the volume was calculated With laser engraving all anilox
using trigonometric formulae. manufacturers had to evolve their
In the early days of anilox measurement most measurement system from the simple
anilox engravers used a chart to give an indication chart method of volume measurement to
of the cell volume. However, there can be a large a more sophisticated method. This was the
difference in volumes due to the shape of the cells. Liquid Volume - Ink drawdown method. Phill Hall, MD
of Troika Systems

CELL SHAPES
X X

Y
SHARP PYRAMID Y SHARP CELL
(Opening to depth ratio of 3:1)
X X

Y
FLATTENED PYRAMID Y
NORMAL CELL
X X

Y
FLATTENED PYRAMID, Y
U-SHAPE STRAIGHT
STRAIGHT CUT CUT, WIDE BOTTOM

January 2018
84 | History of anilox volume measurement

LPI/LPCM Minimum Maximum Percentage difference between

cm3/m2 reading cm3/m2 reading manufacturers readings
Band 1 1200/500 1,70 2,80 65%
Band 2 1000/400 2,63 4,00 52%
Band 3 800/320 1,99 4,80 141%
Band 4 700/280 4.,50 8,30 84%
Band 5 500/200 5.,12 9,80 91%
Band 6 400/160 6,25 12,80 105%
Band 7 300/120 8.,15 12,40 52%
Band 8 250/100 10,60 15,30 44%
Band 9 200/80 14,80 18,90 28%
Band 10 180/70 13,90 20,92 51%
Band 11 150/60 16,70 27,50 65%

Liquid Volume - Ink drawdown method were only able to achieve a minimum 16
While the Liquid Volume test was the first percent variations in their measurements
positive step towards attempting to improve on a 5-banded master roll, and when
volumetric measurement and was adapted similar tests were carried out at another
“The evolution of anilox by many anilox manufacturers as described
above it certainly could not claim to be an
international anilox manufacturer using
six experienced operators on a banded
manufacturing has accurate or consistent method of volumetric roll, the best results still showed a
measurement. variation of 14 percent. These variations
bought many advantages It attempted to follow a similar process to are beyond what is acceptable as
to all users: they are the press by dispensing a known amount of
ink which was spread by a doctor blade onto
measurement variations today.

now produced to a high the anilox. The area the ink spread over was • If the anilox has been through a cleaning
measured in square millimeters, and using the bath it needs to cool down to room
standard of consistency formulae of ink volume/square area (cm3/ temperature before measurements can
m2 or BCM/inch2) a volume was calculated. be taken, if it is warm the ink used for the
and repeatability which Whilst this method was a positive step measurements evaporates and gives very
was not possible even a forward over the original mechanical method
of volumetric calculation, it is prone to many
inaccurate readings.

decade ago” opportunities for errors as follows: • This method is not suitable to measure
open cell structures such as tri-helical
• If the ink density is not absolutely or other complex open cell structures
This difference was proven in research constant variations in measurement because it simply flows out of the open
carried out by Troika Systems in 2007, when will occur. Therefore, if there is a density cell structures and does not fill the cells
a banded roll with 12 engravings from difference between the pots of ink, or the as needed for this kind of measurement.
100-1200 LPI was taken to 15 different ink in the pots evaporate at all during use,
anilox manufacturers, in Europe and North a very real variation in measurements is Therefore, it is not surprising that when
America, to be measured by them using the seen. anilox manufacturers were taking their
measurement method they were using at that measurements using Liquid Volume test
time. • Studies have shown very significant method (nicknamed ‘Squirt and Scrape’
The results shown on the chart variations between operators. In October method by some users) printers found they
demonstrate the maximum and minimum 2010, at Clemson University in North would get different densities from anilox
volumes stated by the manufacturers. With Carolina, the American FTA carried out a which were stated to be of the same volume.
these significant variations on each band it is gauge repeatability and reliability (R&R) Fortunately very few anilox manufacturers
no wonder converters have such elongated study on the variety of rolls measured use this method today.
press set-up times and so much waste. Nor is which had different circumferences and
it a surprise that coating companies waste so different screen counts. The study, done Digital methods of anilox cell volumetric
much solution when they have so little idea of under controlled conditions, showed measurement
what the actual solution carrying capacity is average variations of in excess of ±10 Fortunately, towards the end of the
on their rollers. percent using the Liquid Volume method 1990s electronic systems of volumetric
As higher anilox screens and new elongated of measurement. Which meant that measurement started to evolve. These used
cells and open cell structures evolved, the a 5 volume anilox was measured at interferometric measurements and gave
need for volume measurement could not anything between 4.5 to 5.5 volume; far good reliable readings but are very vibration
be done by conventional methods and beyond the requirements printers need sensitive, expensive and would not survive
measurement systems had to evolve. This to manage their aniloxes for optimal long in the print shop environment, so were
variation between what should have been productivity and minimizing set-up impractical for converters.
comparable aniloxes has been very costly to waste. It is interesting to note that at From 2005 the Troika AniCAM with the
all flexo printers from the smallest of narrow subsequent tests at one global anilox Anilox QC made its first appearance and over
web to the huge corrugated sites. It was time manufacturer, eight of their competent the years evolved to meet the demands of
to help them save costs and time. and experienced Liquid Volume users the large print groups who recognized what

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86 | History of anilox volume measurement

“This is not the end of

the story. There are some
interesting developments
on the horizon with different
materials being used in the
production of aniloxes”

equipment proved with the use of high-end historic values used by the 38 plus anilox
digital analysis using laboratory interferome- manufacturers around the world. It would be
ters the volume of cells. very difficult for the anilox manufacturers to
In comparative tests between the high-end change their historic measurement values, so
interferometer at WCPC at Swansea a solution needed to be implemented.
the cost benefits to them would be if they University and the AniCAM, it was found the The solution was to export from the Anilox
could know what the condition and volumes measurements on all 12 bands were very QC both values of measurement (this is done
of their anilox inventory. comparable, and Dr Deganello stated that the in the anilox manufacturers special version
The demands of the label groups (Coveris, measurements were certainly well within the of the Anilox QC application), so if an anilox
CCL etc), wide web groups (Bemis, Amcor etc) requirements needed in our industry. manufacturers original measurements are
and corrugated groups (DS Smith, Mondi etc) different to the accurate readings they can
can best be summarized by the requirements Calibration for accurate measurements: export both the accurate value and their
of a world leading carton print group, which Most important for accurate volumetric individual standard values to the anilox roll
are: measurement is calibration: this is required information sheet.
• Accuracy: of ±0.1 cm³/m² for process in all three axis. X & Y axis are relatively So, if the manufacturer’s value was 10
aniloxes simple using an optical graticule, which is percent higher than accurate, a 10.1 volume
• Repeatable measurements of ±0.1 cm³/ small glass surfaces with a grid etched onto roll, measured with a historic measurement
m² when measured on the same place them at 100 μ spacing allowing for very method, would show as 9.3 using the
• Inter-operability: the ability for different accurate calibration in the X & Y directions. accurate measurements.
operators to get the same readings Depth measurement needs to be particularly Provided the anilox manufacturers have the
• Ease of use with data archiving for anilox accurate to give the exact depth, and with correct version of Anilox QC application, they
inventory management the X & Y data the depth is used to calibrate have the ability to export both values.
• No time, or minimal time, lost in the units to give the exact volume of the
production due to measurement times cells. Conclusion
Calibration for depth is achieved by The evolution of anilox manufacturing has
All of these objectives were achieved using scanning a very small sphere (ball bearing) bought many advantages to all users: they
the AniCAM with Anilox QC with inventory of a known size, which logically is the same are now produced to a high standard of
management (Anilox Management System), dimension in all three axis. Spheres have consistency and repeatability which was
however ‘accuracy’ of measurement was been used as a method of calibration by not possible even a decade ago. With the
the biggest obstacle – simply because it some interferometer manufacturers since evolution of the anilox there was a need for
had never been proven. This gave all anilox 1998 and is known to be mathematically accurate and reliable measurement, giving
manufacturers the ability to argue that their accurate. With this system of measurement flexo printers the ability to manage their
own measurements were correct on historical and calibration, the industry had at long anilox inventory to a point where press set-up
grounds, and the other anilox manufacturers last a mathematically proven, accurate time is optimized and make-ready waste is
were wrong – not a very satisfactory measurement standard to work from. reduced to a more practical minimum.
situation for the industry. Consequently, in 2013, Troika Systems This is not the end of the story. There
With the significant differences in developed a method of using a sphere of a are some interesting developments on the
measurement standards used by all the anilox known size as a valid reference standard for horizon with different materials being used
manufacturers in the 2007 research, who was dimensional and volumetric measurement in the production of aniloxes. Also, now
right – if any? and hence the AniCAM Calibration Program volumetric measurements can be accurately
(ACP) was developed so users could calibrate measured, we can progress to analyzing and
Accurate anilox volume measurement their AniCAM, usually annually, or as optimizing ink release characteristics with
The accurate measurement of cells was frequently or infrequently as desired. different cell structures optimized for the
proven in 2007 by Dr Davide Deganello individual print or coating processes. It’s still
(pictured) at Swansea University, Welsh Anilox measurements value conflicts a very exciting time in flexo.
Centre for Printing and Coating (WCPC), Clearly there is a conflict between
under the leadership of Professor Tim the accurate, mathematically proven Phil Hall founded Troika Systems in
Claypole, one of the leading print universities measurement system used by many 1996. Go to www.troika-systems.com
in Europe. Dr Deganello’s thesis and hundreds of printers globally, and the for more information

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